N KL OPERATING INSTRUCTION

PSJ150 Batch Pre-expander

张 家 港 市 纽 凯 利 机 械 制 造 有 限 公 司

N KL NEW KALI（EPS）INDUSTRIAL CO., LTD

Operation Manual

Batch pre-expander

Add: No.3, ZhenXingZhong Rd , ZhangJiaGang city,

Jiangsu Province , China

FAX: 0086-512-58989075

TEL: 0086-512-58987731

Mobile phone: +8613773279942

http://www.nkl.cn/

Email: changyx@nkl.cn
1
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

1.Generalization
PSJ150 automatic pressurized intermittent batch pre-expander is newly designed and made

by our company according to the latest international and domestic marketing requirements,

used for first and second expansion. This type of EPS machine is an automatic expanding

system, composed of pressurized batch pre-expander, fluidized bed drier, sieving,

delumpling, screw conveyor and etc making an fully automatic cycle foam system. It is an

essential machine for EPS factory.

Expanded EPS beads through aging under normal pressure can be provided for EPS

molding machine to make different shapes of packing products as well as different sized

blocks. They are ideal packing materials for household appliance, gauges, instruments,

chinaware, glassware and all sorts of valuable and fragile things. Blocks can be used in

house construction, cars, ships, refrigerators etc, because they are good material of sound

insulation, heat insulation and vibration proof.

Main features:

1. Use PLC control system to fulfill automatic working cycle.

2. Pipe system is simple, which is convenient for maintains and repair.

3. Using a 2.2kw motor for filling and discharging makes the filling and discharging

much faster than before and reduces energy consumption.

4. The applying of screw conveyer for filling and electronic weighting scale relieves

working density and improves the production efficiency.

5. The chamber is totally closed which ensures high thermal efficiency and steam saving
2
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

and excels consistent pre-expander in energy saving with 50 percent of energy using.

6. With electronic weighing system and level sensor to control material position, so as to

control expanded density. We control density tolerance within 3 %.

7. With fluidized bed drier, we can carry out automatic cycle of drying, sieving,

deplumping and transporting to silos (with blower).

8. The electronic appliances, pneumatic components and valves are all international and

domestic famous brand which ensures good performance, stability, reliability and long

life.

3
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

2. Main Specification and Technical Data

NO. NAME UNIT PARAMETERS

ф1500（internal diameter）
1 Expansion chamber mm
×2480（height）

2 Effective volume m3 3

Entry port mm DN50

3 steam
Working pressure Mpa 0.6-0.8

Entry port mm DN50

Compressed
4 Working
air Mpa 0.6-0.8
pressure
Upper drainage mm DN 80
5 Draining port
Lower drainage mm DN 80

Main axis motor kW 7.5

Discharging motor kW 2.2

Drying motor kW 5.5

Connected Transporting blower kW 5.5

6
load De-lumping motor kW 0.55

Vibration motor kW 0.18

First filling motor kW 2.2

Second filling motor kW

4
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

Secondary

foaming ｍ３/ｈ 600Kg/h

efficiency
7
12 g/l 600Kg/h
First foaming
15 g/l 900 kg/h
efficiency 20 g/l 1200 kg/h
30 g/l 1500 kg/h

8 Density tolerance within 3%

9 Dimension (l×w×h) M 4310×4150×5120

10 weight T 5

Note: 1.With the constant development and improvement of machine technique, machine

structure and accessories may have some difference from that on operating

instruction, We keep the right of changing and explaining.

2.If you found the annex not match with the packing list in machine acceptance or there

are questions about operation, please contact with the QC department of our company.

You should send us main specifications and serial number and so on.

3. Company reserves the final interpretation of the company's products.

5
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

3. Shape of the machine

4. Running Machine
1. Be sure to check the spindle speed reducer is full of the gear oil or not before starting.

Oil-free operation is strictly prohibited.

2. Saturated steam, steam pressure 0.6-0.8Mpa, dynamic pressure 0.12-0.15Mpa. To use

saturated steam is very important, since if steam pipe too long and too thin, boiler pressure

not enough, aqueous vapor will occur. If unsaturated steam enter expansion chamber, EPS

material will have more water content and easy to form lump, and the expanded density

cannot be even. So for better expansion, the diameter of steam pipe inlet should be over

40mm, and machine near boiler or steam holder.

3. Compressed air should be purified, no water and no dust, working pressure 0.6-0.8Mpa, In

batch pre-expander, compressed air is used for controlling valves and air cylinders,

cleaning chamber and pipes. Centers of solenoid valve are highly sensitive, they are easy to

be block when meeting dirty air and valves burnt from overloading. So compressed air

should be filtered through 40um filter before entering machine to make sure of normal

working.
6
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

4. EPS material should be dried no-powder material within period of validity. If material

exceed time of validity, patent in material escaped out, then they cannot be expanded to the

desired density. Powder is easy to block filling port and steam holes of expansion chamber,

leading to lumps and uneven density.

5. Supplied power 3 phase 4 lines, 50HZ, 380V, connected load 26kW. Machine should be

earth-connected. Before connected with intermittent pre-expander, user should mount an

air control switch near machine for controlling general power

5. Preparation for Running Machine

Ⅰ. To check electric system

1. Supply power 380V, connected load 26kW. Electric box has a wire hole at the bottom for

connecting power supplier. Its shell should be well earth connected. When power supplied,

be sure that indicating light on control panel is on. Check rotating direction of motors, such

as screw conveyor motor, backpressure filling motor, main shaft motor, discharging motor,

drying motor, transporting motor, delumping motor and vibration motor. Check motors

action and noise.

2. Check positions of level sensor, discharge gate sensor, light sensor. Check whether their

positions are right and in correspondence to PLC.

3. Check pressure gauge switch, turn the pin with hand to see if PLC input light on and wire

connection is correct.

Ⅱ. check piping system

1. Check oil lubricator, keeping enough 10# engine oil (must use light oil) in it.
7
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

2. Check steam pipe and compressed air pipe. Fill compressed air in machine, open all

solenoid valves with touch screen. Check whether NO, NC valves are compliant with

piping diagram.

3. Adjust steam pressure relief valve, making its outlet pressure 0.12Mpa. Open steam valve

via touch screen, check whether valve outlet pressure is steady. When pressure comply

with set value, tighten the adjusting screw.

4. Adjust compressed air pressure gauge upper limit to 0.75Mpa, lower limit to 0.45Mpa,

pressure gauge on chamber upper limit 0.05Mpa (chamber protective pressure).

6. operating instruction
Check piping system, level sensors, weighing system and steam proportional valve system

before operating the machine.

1. First remove condensate in steam pipes and in compressed air filters.

2. Turn on Power, startup main shaft motor through touch screen, close discharge gate and

start all motors in fluidized bed drier.

3. Switch to “single step” picture, decide EPS raw material volume according to Parameter

Reference Table. Enter values of raw material volume, fast discharge, slow discharge and

balance on touch screen

4. In single step, preheat expansion chamber to around 100℃.

5. Limit the upper temperature under 120℃.

6. Filling and filling port clean, filling time should be lasting until all material in loader are

poured out into chamber.

8
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

7. Open the gate.

8. Discharge and clean: discharging time is set until all material in chamber poured out.

Bottom clean: after discharging, fill compressed air from chamber bottom to blow out

material in steam holes, time is 2-4 seconds.

9. Windows clean start from begin ‘heating’ and end until finish ‘bottom cleaning’, it is

discontinuous blowing, usually 0.5-1.5 seconds each time.

10. Close discharge gate (controlled by a stroke sensor).

11. When first clean discharging gate, transporting motor, vibration motor and delumping

motor start to run (drying motor starts when expander main agitator run). To get to know

expansion density, measure material at dryer outlet.

Measuring EPS density with electronic scale, if density has great tolerance, try the following

solutions:

(1)Increase or decrease EPS raw material

(2) Change position of level sensor.

(3)Increase or decrease warming time.

When expanded density is adjusted near the desired density, turn to “auto” and run automatic

expanding.

12.You can select manual, single step, semi-auto and auto on touch panel. Usually manual is

for testing actions of all valves, motors and level sensors. Single step and semi-auto are for

adjusting expanding density, while auto is for automatically running.

9
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

7. Touch screen

10
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

11
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

12
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

8.Electrical diagrams

9.Machine Maintenance
1. Clear all material in expansion chamber and in fluidized bed drier before every shift ends.

2. Cut off power supply of screw conveyor, electronic scale, fluidized bed drier and

preexpander.

3. Close compressed air and steam valves.

4. Everyday before working, check chamber to remove lumps and other objects, and check

agitating rods.

5. Everyday before working, check air filter and oil lubricator. Remove water in filter and add

oil (light engine oil) in lubricator if necessary, usually add to 2/3 of the cup.

6. Check vent port and trap to remove blocks. Make sure water flow out of drain port when

working.

7. Often check actions of pressure gauge, temperature gauge, current gauge, volt gauge and

motors. If finding breakage or malfunction, change or repair immediately, ensuring their

reliability and sensitivity.

8. Often check all valves and pipes, especially copper tube of safety valve and pressure gauge

switch. Before machine delivery, safety valve is set to 0.5Mpa, usually users needn’t adjust

again, but every week manually test it in case of malfunction. Pressure of expansion

chamber is controlled by pressure gauge switch, while copper tube is the connection

13
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

between chamber and pressure gauge switch. So once copper tube blocked, pressure gauge

switch cannot display chamber pressure correctly and cannot control pressure correctly,

easy to cause chamber breakage. In view of the importance of copper tube, try to protect it

carefully, especially in winter days since it is easy to break in cold area.

9. Check electronic scale periodically, if it’s not precise, ask professional person to adjust or

repair it.

10. Check earth connection periodically.

11. Often check sealing of Φ80 butterfly valve on filling port and vent port. Remove sealing

immediately when finding breakage or leakage.

12. Keep windows clean and no dust, otherwise, sensitivity of level sensor will be influenced.

10. Safety Notice and Attention

1. If power fails, steam valve will automatically close and compressed air valve open for

cooling, avoiding lumps in chamber. Open discharge gate manually, drive material out with

blower or compressed air.

2. When using the preexpander, make sure that compressed air working pressure more than

0.5Mpa (5kg). All valves are controlled by compressed air, especially the discharge gate.

Discharge gate is locked by air cylinder, air pressure decrease will cause gate open. To run

machine normally, compressed air pressure should be ensured.

3. Before reparation, main power must be cut off. After repairing, remember to take all tools

and accessories out of machine, since they tend to break steam plate and plough plate in

chamber.
14
N KL OPERATING INSTRUCTION
PSJ150 Batch Pre-expander

4. When producing, prevent objects (small stones or iron chips) from entering in chamber

with material, since they are easy to break steam plate.

5. In producing, often check sensitivity of pressure gauge switch, repair or change in time

when finding problems.

6. Machine warning light on in following cases:

A. motor overload, thermal relay released

B. no material for filling in loader

C. discharge gate switch not in right position

D. compressed air pressure lower than set value of pressure gauge switch.

E. Expansion chamber pressure higher than set value of pressure gauge switch.

15